Method and Apparatus for Forming and Mounting a Photovoltaic Array

ABSTRACT

A photovoltaic (PV) module framing and coupling system enables the attachment of PV modules to a roof or other mounting surface without requiring the use of separate structural support members which attach directly to and span between multiple PV modules in a formed PV array. The apparatus provides a parallel coupling for securely interlocking the outside surfaces of parallel frame members together in a side to side arrangement to form an array with improved structural load distribution. The coupling may attach to a slot in the frame at substantially any position along the length of the frame thereby enabling the interconnection of adjacent PV modules along both an x and y axis. The apparatus may further provide a rotating portion and locking portion, mounting brackets for direct connection to a mounting surface, grounding teeth, and a twist-lock engagement means for interlocking and aligning PV modules in the array.

CROSS REFERENCES

The present application is a continuation of application Ser. No.13/351,397, filed Jan. 17, 2012, which is a continuation of applicationSer. No. 12/594,935 filed Oct. 6, 2009, now U.S. Pat. No. 8,109,048,issued Feb. 7, 2012. The foregoing applications are incorporated byreference in their entirety as if fully set forth herein.

BACKGROUND

Photovoltaic (PV) modules and related mounting hardware are well knownand in widespread use. The most common mass-produced PV modules in usetoday include a laminated portion, or PV laminate, and a frame portion,and are designed specifically to convert light into electricity. The PVlaminate portion is for encapsulating solar cells in a substantiallyflat, weather-tight envelope comprising a laminated construction ofvarious layers including but not limited to glass, clear plastic,encapsulant material (like EVA), active photovoltaic material,interconnecting conductors between solar cells, and a protectivebacksheet (like PVF film or glass). Photovoltaic laminates are commonlymanufactured today in rectilinear shapes like squares, rectangles,triangles, and trapezoids and, due to their fragile nature, are usuallycompletely enclosed by a permanent, substantially rigid, glued-on frameportion which holds and protects the delicate edges of the PV laminateportion and provides a means of supporting the PV laminate and attachingit to other objects without damaging the PV laminate. The combination ofthe PV laminate portion and the glued-on frame portion is referred toherein as a PV module or framed PV module. The present invention relatesto integral frames for standard PV laminates, and to the associatedmounting hardware which attaches to the integral frames for the purposeof securing the PV module to a roof or support structure.

U.S. Pat, No. 5,571,338 to Kadonome, et al. discloses a photovoltaicmodule comprising a photovoltaic panel having a top edge and a bottomedge. An exterior frame structure attached to edges of the photovoltaicpanel defines an upwardly open groove extending along at least the topand bottom edges of the panel to direct rain water away from theunderside of the panel.

U.S. Pat. No. 7,406,800 to Cinnamon describes an integrated module frameand racking system for a solar panel. The solar panel comprises aplurality of solar modules and a plurality of series couplings orsplices (in the form of series couplings) for coupling the plurality ofsolar modules together. The plurality of splices provide a way to makethe connected modules mechanically rigid both during transport to theroof and after mounting for the lifetime of the system, provide wiringconnections between modules, provide an electrical grounding path forthe modules, provide a way to add modules to the panel, and provide away to remove or change a defective module. Connector sockets areprovided on the sides of the modules to simplify the electrical assemblyof modules when the modules are connected together with splices.

U.S. Patent Application 20070074755 by Eberspacher, et al. teaches aphotovoltaic module with a rigidizing backplane. A solar cell moduleincludes one or more photovoltaic (PV) cells arranged in a substantiallyplanar fashion. Each PV cell has a front side and a back side. The PVcells are adapted to produce an electric voltage when light is incidentupon the front side. A rigid back plane is attached to the PV cells suchthat the back plane provides structural support from the back side. Therigid back plane includes a structural component having a plurality ofvoids.

The foregoing examples of the related art and limitations relatedtherewith are intended to be illustrative and not exclusive. Otherlimitations of the related art will become apparent to those of skill inthe art upon a reading of the specification and a study of the figures.

SUMMARY OF THE INVENTION

The method and apparatus for forming and mounting a photovoltaic (PV)array of this invention provides a PV module framing and coupling systemwhich enables the attachment of PV modules to a roof or other mountingsurface without requiring the use of separate structural support memberswhich attach directly to and span between multiple PV modules in aformed PV array. The following embodiments and aspects thereof aredescribed and illustrated in conjunction with systems, apparatus, tools,and methods which are meant to be exemplary and illustrative, notlimiting in scope. In various embodiments, one or more of theabove-described problems have been reduced or eliminated, while otherembodiments are directed to other advantages or improvements.

The inventive apparatus may provide a slidable parallel coupling forsecurely interlocking the outside surfaces of parallel frame memberstogether in a side to side arrangement, thereby enabling the formationof a PV array with improved structural load distribution. The inventivecoupling member may attach to a slot in the frame at substantially anyposition along the length of the frame thereby enabling theinterconnection of adjacent PV modules along both an x and y axis. Theinventive apparatus may further provide a rotating portion and lockingportion for coupling to frame attachment, mounting brackets for directconnection to a mounting surface, grounding teeth for the automaticcreation of a reliable two axis grounding matrix, and a rapid twist-lockengagement means for reliably interlocking and aligning PV modules inthe array.

In addition to the exemplary aspects and embodiments described above,further aspects and embodiments will become apparent by reference to thefigures and by study of the following detailed descriptions.

BRIEF DESCRIPTION OF THE DRAWINGS

Demonstrative embodiments are illustrated in referenced figures anddrawings. It is intended that the embodiments and figures disclosedherein are to be considered illustrative rather than restrictive.

FIG. 1 is a perspective view of a PV module with a hybrid, strut-likeframe;

FIG. 2 is a perspective view of a parallel coupling;

FIG. 3 is a cross-section cut through two adjacent PV modules;

FIG. 4 is a perspective view of two adjacent PV modules coupledtogether;

FIG. 5 is a perspective view of a height adjustable bracket;

FIG. 6 is a cross-section cut through two adjacent PV modules;

FIG. 7 is a perspective view of building with a PV array attached to aroof;

FIG. 8 is a side view of the PV array of FIG. 7 at a larger scale;

FIG. 9 shows a typical prior art PV array;

FIG. 10 is a perspective view of the PV array of FIG. 7 viewed from theback;

FIG. 11 is a cross-section cut through a PV array just above thecouplings;

FIG. 12 is a simplified top view of two adjacent rectangular frames;

FIGS. 13-14 show generic PV arrays comprising four PV modules withadjacent frame members;

FIG. 15 shows a prior art strutless PV array;

FIG. 16 is a perspective view of a coupling;

FIGS. 17-18 are front and back side views respectively of a coupling ina first position;

FIG. 19 is a perspective view of a coupling;

FIGS. 20-21 are front and back side views respectively of a coupling ina second position;

FIG. 22 is a perspective view of a coupling;

FIGS. 23-24 are front and back side views respectively of a coupling inthird position;

FIGS. 25-31 depict a second embodiment of the present invention;

FIGS. 32-34 depict a third embodiment of the present invention;

FIGS. 35-38 depict a fourth embodiment of the present invention;

FIGS. 39-40 are a perspective view and a cross section cut between twointerlocked PV modules;

FIGS. 41-42 are a cross section cut between two interlocked PV modulesand a perspective view of a coupling;

FIGS. 43-44 are a perspective view and a cross section cut between twointerlocked PV modules;

FIGS. 45-46 are a perspective view and a cross section cut between twointerlocked PV modules;

FIGS. 47-48 are a cross section cut between two interlocked PV modulesand a perspective view respectively for an alternate embodiment;

FIGS. 49-50 depict a further alternate embodiment;

FIGS. 51-52 depict a further alternate embodiment as installed on anopen canopy structure;

FIGS. 53-54 show an alternate embodiment of a PV array with a snap-inconduit box; and

FIG. 55 depicts a perspective view of a further alternate embodiment ofa PV module.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIGS. 1 through 55, wherein like reference numerals referto like components in the various views, there is illustrated therein anew and improved framing and mounting system for photovoltaic arrays,generally denominated 10 herein. While various terms may have theirordinary meaning or particular meaning in the art, for ease ofunderstanding there is provided herein, both below and at otherlocations in this specification, a non-limiting explanation as to theminimum scope intended for understanding of the present specification.Terms may be in singular or plural or any tense while retaining the samegeneral meaning Photovoltaic is abbreviated as “PV”. PV laminate refersto an encapsulated group of solar cells. Frame refers to a group offrame members (typically four for a rectangular-shaped PV module) whichsupport and provide rigidity to a PV laminate. PV module refers to asingle, one-piece, individually deployable electricity generating devicecomprising a PV laminate, a frame, and at least two output wires. A PVarray refers to a group of PV modules which are deployed together andare a part of the same electricity generating system. A mounting rail orstrut is a structural member which connects to the bottom of a PV modulevia the use of a separate fastener (such as a coupling, bolt, etc.) andwhich serves to mechanically link two or more PV modules together,thereby providing structural support for the modules and also providinga means for connection to a mounting surface.

First Embodiment—Structure

FIGS. 1-24 depict a first embodiment of the present invention. FIG. 1provides a perspective view of a photovoltaic or PV module 11 with ahybrid, strut-like frame 12. Each PV module is made of substantiallyidentical construction. As is typical in the art, frame 12 comprisesfour frame members 13 which are assembled around PV laminate 20 andsecured by optional adhesive between frame members 13 and laminate 20and frame screws 18U, 18L at the corners. The complete PV module 11 istypically assembled in this way at a PV module manufacturing facility;then a plurality of one-piece PV module assemblies 11 are transported toa particular job site and mounted to a building or other structure toform a PV array 10. In other embodiments we contemplate the assembly offrames 12 around PV laminates 20 at the final installed location. Thus,the exact location of the manufacturing and assembly steps isnon-critical with regards to proper implementation of the presentinvention.

Hybrid, strut-like frame 12 may include substantially similarconstruction on all four sides of PV module 11. Top surface 14 of frame12 is the surface which faces the same direction as the cells (notshown) in PV laminate 20. Frame outside surface 16 comprises amultifunction female channel portion or slot 26 for the purpose ofinterlocking PV modules 11 together and connecting to a roof or othermounting surface as will be discussed below. Frames 12 as shown herehave the corners cut to allow for a typical butt joint. In otherembodiments the frames are joined at the corners via a mitre joint.Furthermore, any of the typical methods for joining framing members atthe corners is applicable and covered in the scope of the presentinvention. Corners may also be fashioned to allow insertion of couplingsfrom the corner and to allow smaller couplings to slide around thecorner in a formed array. PV module 11 further comprises positive 22posand negative 22neg output cables with positive 24pos and negative 24negplugs as are typical in the art. In other embodiments multi-conductorcables are utilized. Output cables 22pos, 22neg originate in arear-mounted electrical box 21.

FIG. 2 depicts a perspective view of an interlocking device or parallelcoupling 50 a which may be utilized to interlock the outside surfaces 16of two adjacent PV module frames 12 via a twist-lock action. This firstembodiment contemplates a one-piece parallel coupling 50 a comprising arotating portion 100 with shaft portions 102A, 102B protruding from eachside. The end of shaft portion 102A comprises a first key or lockingportion 104A, and the end of shaft portion 102B comprises a second keyor locking portion 104B. Both locking portions 104A, 104B rotate withthe shaft portions 102A, 102B upon rotation of rotating portion 100 witha wrench.

Rotating portion 100 further comprises an optional top spring 106U andbottom spring 106L to help account for variations in material andassembly tolerances, to mitigate thermal expansion and contractionvariance, and to provide a force which resists the unlocking of twointerlocked PV modules 11. Bores 110U and 110L (not viewable here) inrotating portion 100 are provided to house and structurally supportsprings 106U, 106L respectively. Springs 106U, 106L are shown here ascylindrical springs and may be made from spring steel or other suitablespring material. Other embodiments contemplate springs of other typesand shapes, and still other embodiments provide coupling 50 a withoutsprings since frame 12 under compression provides some spring force. Forexample, disc washers, wave washers, star washers, finger springs,spiral springs, polyurethane springs, and others are all suitable foruse with the present embodiment under discussion. Rotating portion 100comprises four flat faces 116 so that rotating portion 100 can be easilyturned with a typical wrench from above. One skilled in the art willrecognize that the number of flat faces could vary and rotating portion100 could be simply rounded, slotted, bored, or knurled depending on thetype of wrench which is utilized. Shaft portions 102A, 102B furthercomprise optional reduced diameter portions 114A, 114B to help guide andhold a free PV module 11 which is being moved into position forcoupling. Rotating portion 100 (except for springs 106U, 106L), shaftportions 102A, 102B, and locking portions 104A, 104B may be machinedfrom a single piece of solid metal, such as steel or aluminum. Inanother embodiment rotating portion 100 may be made of a light-weightmaterial such as plastic. However, one skilled in the art will recognizethat multiple components could be assembled together and variousmaterials could be used to form the various portions of coupling 50 a asdescribed herein.

Expanding the discussion now to further include FIG. 3, which depicts across-section cut through two adjacent PV modules 11A, 11B which arecoupled together with a coupling 50 a, it can be seen that first lockingportion 104A may be specially shaped to be the first of the two lockingportions 104A, 104B which is inserted into a first slot 26A of PV module11A. Locking portion 104A may be provided with curved surfaces 118U,118L on opposite corners which allow locking portion 104A to be rotatedin a clockwise manner inside of slot 26A until locking portion stops120AU, 120AL contact upper 122AU and lower 122AL inside surfaces of slot26A respectively. With reference to FIGS. 16-24, which will be discussedin more detail below, one skilled in the art will recognize that thewidth of locking portion 104A is slightly less than the height A ofopenings 27A, 27B in slots 26A, 26B, while the length is approximatelyequal to the height B inside of slot 26A. Therefore locking portion 104Amay be inserted when it is oriented in a first position 91 and capturedbehind male features or flanges 108AU, 108AL when it is rotatedclockwise. After approximately 90 degrees of clockwise rotation, whenlocking portion stops 120AU, 120AL are reached coupling 50 a is said tobe in a third position 93 (see below for discussion of an intermediatesecond position 92).

Accordingly, second locking portion 104B may be specially shaped to bethe second of the two locking portions 104B, 104A to be inserted into asecond slot 26B in PV module 11B. This first embodiment contemplates ashape for locking portion 104B which is capable of passing between malefeatures or flanges 108BU and 108BL for approximately the first 45degrees of clockwise rotation of coupling 50 a. Thus the intermediateposition of approximately 45 degrees of clockwise rotation is said to bethe second position 92. The shape of locking portion 104B is similar tolocking portion 104A except that material has been removed in theclearance zones 124U, 124L directly opposite curved surfaces 118U, 118Lon locking portion 104A. Thus, orientation of coupling 50 a in firstposition 91 and insertion of locking portion 104A into slot 26A followedby a rotation to second position 92 results in locking portion 104Abeing captured by slot 26A and locking portion 104B being correctlyoriented for insertion into slot 26B. Furthermore, insertion of lockingportion 104B into slot 26B followed by an additional rotation ofapproximately 45 degrees clockwise to third position 93 results inlocking portion 104B being captured by slot 26B. Rotation ceases whenlocking portion stops 120AU, 120AL contact surfaces 122AU, 122AL insideslot 26A and locking portion stops 120BU, 120BL contact surfaces 122BU,122BL inside slot 26B, and at this point the outside surfaces 16A and16B of PV modules 11A and 11B are said to be coupled or interlockedtogether (these two terms are used interchangeably throughout thisdocument). Other embodiments contemplate a number of variations on thelocking portions 104A, 104B and the slots 26A, 26B, all of which arewithin the scope of the present invention. For example, some embodimentsmay utilize locking portions 104A, 104B which are identical in shape butsimply rotated at different angles from each other relative to shaftportions 102A, 102B. Such embodiments are still capable of providing asolid interlock but do not allow removal of a single module from themiddle of a completely installed PV array 10 since first position 91 canonly be reached when locking portion 104B is not inside slot 26B. Otherembodiments include locking portions which are shaped for differentangles of rotation other than 45 and 90 as discussed above, while othershave locking portions which are shaped for counter-clockwise rotation.

Locking portions 104A,104B further comprise tapered surfaces 105AU,105AL, 105BU, and 105BL to guide them into position as coupling 50 a isrotated and raised teeth 112AU, 112AL, 112BU, and 112BL for cutting intoframe 12 and ensuring solid electrical ground contact between twoadjacent PV modules 11 when they are coupled together. Teeth 112AU,112AL, 112BU, 112BL also provide structural support by counteractingforces which tend to slide coupling 50 a lengthwise in slots 26A, 26B.In other embodiments teeth 112 are provided in different locations thanthose shown here, and in still other embodiments teeth 112 are replacedby a separate grounding washer, such as a star washer, which ispositioned between a portion of coupling 50 a and frame 12.

As shown in FIG. 3, slots 26A, 26B from two adjacent, interlockedmodules 11A, 11B comprise openings 27A, 27B which allow insertion ofcouplings 50 a in a direction which may be substantially parallel withthe plane of laminates 20A, 20B and substantially perpendicular withoutside surfaces 16A, 16B. Flanges 108AU, 108AL, 108BU, 108BL, which arelocated near openings 27A, 27B create (by virtue of their position)inside surfaces 109AU, 109AL, 109BU, 109BL of slots 26A, 26B which areavailable for use by couplings 50 a and brackets 132 (see below) as abearing surface. Inside surfaces are shown here as being substantiallyperpendicular to PV laminate 20. However, other embodiments providesloped and curved surfaces 109AU, 109AL, 109BU, 109BL.

FIG. 3 further reveals frame inside surfaces 17A, 17B; frame bottomsurfaces 15A, 15B; frame screw holes 19AU, 19AL, 19BU, 19BL for framescrews 18B, 18U; and frame recesses 126A, 126B for capturing PVlaminates 20A, 20B. This view also shows how substantially constantspacing between PV modules 11 in an array 10 is automatically determinedby the width of rotating portion 100, with minor material and assemblytolerance issues being allowed by variable compression amounts onsprings 106U, 106L. For example, manufacturing of a perfectly square PVmodule 11 is very difficult. Therefore it is common for PV modules tohave widths and lengths that vary by up to ⅛″. In prior art systems thisvariance is not accounted for. The springs 106U, 106L as shown hereprovide a degree of compliance that helps to mitigate the compounding oftolerance errors and therefore major problems with proper alignmentduring installation.

FIG. 4 depicts a perspective view of two adjacent PV modules 11A, 11Bwhich are coupled together with two couplings 50 a. Since slots 26A, 26Bmay run substantially the whole length of frames 12A, 12B, couplings 50a may be located at substantially any point along the length. Given thehigh strength connection provided, in practice one to three couplingsper seam between two PV modules is typically adequate. At a corner 130of each PV module 11 the flanges 108AU, 108AL, 108BU, 108BL are cut offthus allowing coupling 50 a to easily slide from the seam between oneset of PV modules 11 over to the seam between an adjacent pair of PVmodules 11 when coupling 50 a is in first position 91 as discussedabove.

Referring now to FIGS. 5-6, FIG. 5 depicts a perspective view of aheight adjustable bracket 132 which is suitable for connection to a PVmodule 11 of the first embodiment of the present invention, and FIG. 6shows a cross-section cut through two adjacent PV modules 11A, 11B whichare coupled together with a coupling 50 a (not picture here for clarity,see FIG. 3). An L-shaped bracket 132 comprises a z-axis or verticaladjustment slot 140 and a y-axis adjustment slot 142 (coordinate systembased on plane of mounting surface, see FIG. 7). A channel bolt 136 withbolt head 137, which is threaded into a channel nut 134, is utilized toattach bracket 132 to outside surface 16B of frame 12B. Channel nut 134is shaped to fit inside slot 26B and to be captured behind flanges108BU, 108BL. This embodiment contemplates a simple rectangular shapefor channel nut 134 with nut 134 being inserted at corner 130 and slidinto position. Threading bolt 136 into nut 134, sliding bracket 132between bolt head 137 and frame outside surface 16B, and then tighteningbolt 136 serves to pull nut 134 solidly against flanges 108BU, 108BLthereby rigidly securing bracket 132 to frame 12B. And since slot 26Bruns substantially the whole length of frame 12B, bracket 132 can beattached to substantially any point along the length, which will bereferred to as the x-axis direction. Therefore, slot 26B along with slot140 and slot 142 allows for 3 dimensional adjustability of bracket 132,enabling greatly simplified installation via much easier lining up ofbrackets 132 with rafters (which typically run in the y-axis direction)and much easier leveling and aligning of PV modules within array 10. Lagscrew 138 provides a means of directly securing bracket 132, andtherefore array 10, to a mounting surface 144, such as a roof withoutany other support structure as is typical in prior art systems.

Please note that while FIG. 6 shows a connection of bracket 132 to rightframe 12B, it can be connected to any outside surface 16, andfurthermore it can be reversed so that lag screw 138 is positionedbeneath the PV module 11 to which it is connected. In other embodimentsnut 134 comprises a rectangular shape with two opposing rounded corners,similar to locking portion 104B, so that it can be inserted into slot26B from any point along frame 12B and then twisted 90 degrees to tuckbehind flanges 108BU, 108BL. In still other embodiments nut 134 is astandard hexagonal-shaped nut.

One alternate embodiment removes lower flanges 108AL, 108BL from slots26A, 26B and the lower portions of locking portions 104A, 104B resultingin a one-sided locking action instead two as with the first embodiment.

First Embodiment—Basic Operation

Referring to FIGS. 7-8 and FIGS. 10-11, a PV array 10 according to thefirst embodiment of the present invention is shown installed on the roofof a building 146. FIG. 7 depicts a perspective view of building 146with PV array 10 shown attached to a roof 144R which serves as asuitable mounting surface 144. Roof rafters 148 are just beneath the topsurface of the roof and are shown as dashed lines. Brackets 132 can beseen in this view along the front of PV array 10. Brackets 132 areoriented such that lag screws 138 are hidden under PV modules. Brackets132 can be seen attached to slots 26 on the outside surface 16 of thelowest row of three PV modules 11, one bracket 132 per PV module 11.Brackets 132 have been adjusted in their respective slots 26 in thex-axis direction such that each bracket 132 lines up with a rafter 148.Since lining up of brackets 132 with rafters 148 is only required withcertain types of roofs and mounting surfaces, other embodiments providebrackets 132 which are not lined up with rafters, but rather attachdirectly to the mounting surface at any desired point. In still otherembodiments, brackets 132 are adjusted in the x and y directions to lineup with ground mounted structures, pier blocks, concrete posts, andspecialized mounting hardware such as roof jacks, mounting posts,mounting jacks, tile brackets, specialized brackets, and stand-offs.Since the inventive system provides three dimensional adjustability, itcan be connected to almost any suitable mounting surface.

FIG. 8 shows a side view of the same PV array 10 from FIG. 7 at a largerscale. This figure helps to clarify the fact that PV array 10 isconnected to roof 144R without the use of strut or other supports.Brackets 132 connect frames 12 directly to roof 144R, and couplings 50 ainterlock PV modules 11 together. In contrast, FIG. 9 shows a typicalprior art PV array 10PA without the benefit of an interlocking system asdisclosed herein. PV modules 11PA are first linked together by struts131PA. Struts 131PA are then attached to a mounting surface (not shown)via brackets 132PA. As can be seen here strut 131PA is a device which isat least as wide as two PV modules 11PA and is designed to support theopposing sides of at least two PV modules 11PA. A coupling, on the otherhand, only joins PV modules together at the seam between the two modulesand therefore is not wider than a single module. The fact that struts131PA are designed to span between modules 11PA means that a lot ofextra material is required. The additional expense and installation timerequired to utilize strut 131PA is a significant drawback to prior artsystems.

FIG. 10 shows a perspective view of the same PV array 10 from FIG. 7except that array 10 is being viewed from the back (exactly 180 degreesaround from the FIG. 7 view) with building 146 removed to reveal theback side of PV array 10. In this view it is now evident that a row ofthree brackets 132 is located along every horizontal seam 150 between PVmodules 11 and along the top 154 and bottom 156 edges of array 10. Thismethod of relatively evenly distributing brackets 132 across array 10 isnot possible with prior art strutless systems which utilize seriescouplings (see discussion below).

FIG. 11 shows a cross-section cut through PV array 10 (from FIG. 7) justabove couplings 50 a and looking perpendicular to array 10 therebyrevealing the locations of couplings 50 a and brackets 132 (roofingmaterial not shown beneath array 10 for clarity). Couplings 50 a areshown interlocking all PV modules 11 in array 10 at all horizontal 150and vertical 152 seams between PV modules 11. In other embodimentscouplings 50 a are only utilized on either horizontal seams 150 orvertical seams 152. The arrangement of couplings as shown here creates adouble structure or parallel interlock support system 160 for array 10along both the x and y-axes as will be discussed below. Each frame 12 isreferred to as a hybrid, strut-like frame because, unlike most prior artsystems, it performs the following basic functions which are normallyshared between a PV frame and a strut or similar structural supportsystem: (a) holding and protecting the edges of PV laminate 20; (b)interconnecting modules 11 together with a structural support system (inorder to increase structural integrity and minimize the number ofrequired connection points to mounting surface 144); and (c) providing ameans for attaching array 10 to mounting surface 144 via foot-type orbracket members.

First Embodiment—Series and Parallel Coupling Theory

FIG. 12 provides a simplified top view of two adjacent rectangularframes A and B. Lines C₁, C₂, C₃, and C₄ represent places along the seambetween the two frames A and B where couplings can theoretically beplaced. Couplings which connect at lines C₁ and C₂ are referred to asparallel couplings since a union of frames A and B at these pointsresults in frames A and B being interlocked in parallel. It follows thenthat any point along the seam between A and B is theoretically capableof receiving a parallel coupling. However, the corner points K₁ and K₂are special cases since prior art slots in the outside surfaces offrames do not extend all the way to the corner on both sides of a pairof orthogonal frame members. This problem arises from the nature of thealuminum extrusion process (which is how most PV frames aremanufactured) and prevents the sliding of parallel couplings all the wayto the end on at least two sides of a rectangular PV module. The cornersare also a special case for a second reason. The corners K₁ and K₂ arethe only places around the perimeter where a coupling can be insertedinto the outside surface of a first frame member B₄ and continue throughinto a second frame member B₃ which is around the corner from the pointof insertion. Thus, lines C₃ and C₄ are shown extending from parallelframe members A₂, B₄ into the orthogonal frame members B₁, B₃ and A₁,A₃. Since the ability to run a coupling into an orthogonal frame memberclearly enhances the structural properties (z-axis loads can bedistributed over a larger area), prior art couplings fall into two basiccategories: parallel couplings which are optimized to connect to theside of a frame member substantially anywhere along the whole length ofthe member and series couplings which are optimized for the special caseof connecting to the ends of frame members at the corner points K₁, K₂.Series couplings are so named because they link two frame members, suchas A₃ and B₃, end to end.

In order to understand the operation of PV array 10 of the firstembodiment, it is important to first understand how the forces that arepresented to PV array 10 are distributed across it. Forces can act overthe entire surface, such a wind pressure, or forces can be highlylocalized, such as someone stepping on it. In either case, these forcesmust find their way to the roof 144R or mounting surface 144 viabrackets 132 that mount the PV system, and these brackets 132 may besome distance away from the point or area of application of the force.In many cases the force must pass across PV modules and the transitionsbetween them in order to make it to mounting surface 144. A couplingdevice for interlocking frame members 13 provides an opportunity tofurther support frame members 13 by locking it to adjacent frame members13. For an individual PV module 11 each frame member 13 acts as aseparate structural entity which is supported by PV laminate 20 andconnected to orthogonal frame members at the corner joints. Even in ahypothetical case of a framed PV laminate which comprises a frameconstructed out of a single piece of material (no such example exists toour knowledge), each side of the frame is still a separate structuralentity since the sides are mostly separated by the laminate and onlyconnected by a small portion in the corners. Thus, it is important todiscuss which frame member and where on the frame member a particularcoupling is connected if one wants to understand the structuralproperties of the coupling. Assuming that PV module 11 comprisessubstantially straight frame members 13, then the possible shapes (in atop view) for flat-plate PV module 11 are a triangle, rectangle,pentagon, hexagon, etc. All such shapes are suitable for use with thepresent invention.

FIGS. 13-14 show generic PV arrays 10P and 10S, comprising four PVmodules 11A, 11B, 11C, 11D with adjacent frame members 13A1, 13B1; 13A2,13C2; 13B2, 13D2; 13C1, 13D1 respectively. These two figures demonstratethe two basic types of couplings which are possible in a rectangulararray: parallel couplings 50 and series couplings 62. Whenstraight-sided PV modules 11A, 11B, 11C, 11D are assembled to formsubstantially rectangular PV arrays 10P and 10S, the result is aplurality of frame members 13 which are immediately adjacent to eachother (within arrays 10P, 10S) and a plurality of frame members 13around the perimeter of arrays 10P, 10S. FIG. 13 shows parallelcouplings 50 that each connect two adjacent and substantially parallelframe members 13 side to side. FIG. 14 shows series couplings 62 thateach connect two substantially collinear frame members 13 end to end.

As shown in FIG. 13, parallel couplings 50 allow a force F₁ applied toPV module 11B to be distributed between the PV modules immediatelyadjacent to it, 11A and 11D, along paths P₁, P₂, P₃, as well as out tothe more remote PV module 11C along paths P₄ and P₅. This distributionof forces is enabled since parallel couplings 50 allow both theconnection of frame members 13 end to end and side to side. For example,frame members 13B1 and 13A1 are interlocked in addition to theorthogonal pair of frame members 13B2 and 13D2. This connection oforthogonal pairs of frame members 13 enables the connection of each rowof PV modules 11A, 11C, to the adjacent row 11B, 11D and allows force F1to be distributed across all the PV modules in array 10P, thusstrengthening the entire frame structure supporting PV laminates 20.However, series couplings 62, as shown in FIG. 14, will only allowforces to be distributed down the rows 11A, 11C and 11B, 11D which areattached in this way. The same force F₁ presented to module 11B in thiscase can only take paths P₁₀ and P₁₁, thus preventing the distributionof loads to PV modules 11A, 11C.

While series couplings 62, as are known in the prior art, are clearlyless advantageous than parallel couplings, some embodiments of thepresent invention, as will be discussed below, provide a means foradding a series coupling portion to a parallel coupling thereby creatinga series-parallel coupling. There are distinct advantages to such ahybrid coupling since in theory a series coupling may provide moreopportunity for enhancing the z-axis strength of frame 12 (though suchpotential is not realized in prior art couplings).

Parallel interlock support system 160 operates as follows. Thespecialized slot 26 allows couplings 50 a to securely connect the sidesof each immediately adjacent and parallel pair of frame members 13. Itis common for installation technicians to step on a PV laminate 20during installation. This action provides a localized load such as wouldgenerate force F₁. In prior art strutless systems, force F₁ istranslated to the frames which are nearest to the point of loading, andeach frame member 13 is acting mostly independently since there are nosecurely connected additional supporting members nearby. In the firstembodiment of the present invention, however, force F₁ presented to thetop of PV laminate 20 is shared by frame 12 which surrounds PV laminate20 as well as the four frame members 13 which are coupled to the loadedPV laminate 20. Thus, it can be seen that a support grid is created bythe simple and rapid connection of couplings 50 a to adjacent frames 12.This grid is evenly distributed in the x and y directions throughoutarray 20, and the doubled support members run beneath the edges of eachPV laminate 20. The result is a PV array 10 which can be mounted to aroof or other mounting surface 144 without the need for costly and heavystrut (or other structural members). Furthermore, the increased spanningcapabilities provided by the parallel interlock support structure 160significantly reduce the number of connection points (and thereforebrackets 132) for a given size array 10 on a given mounting surface 144as compared to prior art strutless systems.

FIG. 15 shows a prior art strutless PV array 210PA with PV modules211PA, brackets 232PA, and series couplings 250PA. As discussed above,series couplings must be connected at the corners and therefore theycannot be used to connect two adjacent rows together. Thus, bracketsbetween rows must be doubled up (as shown) or specialized (and difficultto install) double brackets must be utilized. And, as mentioned above,the total number of brackets 232PA is also increased relative to theinventive device of the first embodiment because spans between brackets232A cannot be as long.

First Embodiment—Coupling Modes

The unique structure of the framing and coupling systems of the firstembodiment enables three distinct modes of operation: positioning mode,locked mode, and sliding mode. In the first embodiment these differentmodes may be easily accessed via rotation of coupling 50 a into one ofthe three discrete positions 91, 92, 93 as discussed above. Otherembodiments access these modes via different means as will be discussedbelow.

Positioning mode is primarily utilized during installation and removalof PV modules 11 in PV array 10. Positioning mode secures coupling 50 ato one PV module 11 of a pair of PV modules 11 to be interlocked. Sincethe positioning of PV modules can be difficult, particularly on slopedroofs, positioning mode insures that coupling 50 a will stay in positionas the two modules are guided together. Thus, in positioning modecoupling 50 a is either firmly secured or loosely attached to one PVmodule 11.

Locked mode is the mode that all couplings are left in once array 10 isfully installed. Locked mode securely interlocks two adjacent PV modules11 together thereby forming a parallel interlock support system 160 asdiscussed above. In locked mode coupling 50 a is firmly secured to twoadjacent PV modules. This mode also automatically grounds the twointerlocked modules 11 to each other and forces them into properalignment and spacing. The automatic grounding feature of the firstembodiment of the present invention provides a substantial improvementover prior art systems because PV modules are electrically grounded toeach other both within rows of modules 11 and between rows. Thus acomplete x-y grounding matrix results so that only one ground wire needsto be run from PV array 10 to the grounding equipment for the site.

Sliding mode is primarily used during installation and removal of PVmodules 11 in array 10. Sliding mode partially decouples two interlockedPV modules so that coupling 50 a may be repositioned or slid all the waydown slot 26 and over into slots 26 for an adjacent PV module pair inarray 10. This allows removal of an individual PV module 11 that issurrounded by adjacent PV modules 11 installed on all sides. Thus insliding mode coupling 50 a is loosely attached to two adjacent PVmodules. Prior art systems do not teach or imply a PV array coupling andframing system capable of achieving all three of these coupling modes(positioning, sliding, and locked).

First Embodiment—Coupling Process

FIGS. 16, 19, and 22 depict a perspective view of coupling 50 a in eachof its three discrete positions 91, 92, 93 respectively as it isutilized to interlock two adjacent frames 12A, 12B together (only aportion of frames 12A, 12B are shown so that locking portions 104A, 104Bare revealed). Please note that since coupling 50 a may be installed ineither frame first, FIGS. 16, 19, and 22 show frames 12A, and 12B inopposite positions than in FIG. 3. FIGS. 17-18 show front and back sideviews respectively of coupling 50 a in first position 91. FIGS. 20-21show front and back side views respectively of coupling 50 a in secondposition 92. FIGS. 23-24 show front and back side views respectively ofcoupling 50 a in third position 93. The following description alsoreferences FIGS. 2-3 since some parts are easier to see in closer views.

The process of interlocking two adjacent frames 12A, 12B is as follows.First, coupling 50 a is oriented in first position 91, which aligns thelength of locking portion 104A with the length of slot 26A, theninserted at substantially any point along frame 12A into slot 26A. Whileinserting, the direction of travel is substantially parallel with theplane of laminate 20A and substantially perpendicular to the length ofslot 26A. Coupling 50 a is inserted until locking portion 104A hits theback of slot 26A or rotating portion 100 contacts outside surface 16A offrame 12A. FIG. 16 shows coupling 50 a in first position 91 and fullyinserted. For convenience, we contemplate alignment of rotating portionflat faces 116 at 45 degrees to the plane of laminate 20 when in firstposition 91: this way the corner point of rotating portion 100 ispointing straight up and is therefore easy to align by eye. Of courseother orientations for flat faces 116 will work just as well. Oneskilled in the art will recognize that springs 106U, 106L are orientedsuch that they are not touching frames 12 in first position 91 (sincethey line up with opening 27A, 27B of slot 26A, 26B). Therefore, areturn to first position 91, even after the complete array 10 has beeninstalled, will enable sliding mode since it is not locked onto eitherframe and since springs 106U, 106L are not compressed.

The second step is to rotate coupling 50 a into second position 92 inorder to enable positioning mode as is depicted in FIGS. 19-21. Thoughlighter duty springs may be used, we contemplate the use of relativelystiff springs for springs 106U, 106L since movement of the modules 11 inarray 10 may be undesirable once the installation is complete. Springswith a full deflection rating of 100 to 500 pounds may work well, butother spring rates are also suitable. Thus, in order to move coupling 50a from first position 91 to second position 92, a wrench is applied torotating portion 100 to rotate it approximately 45 degrees clockwise. Inthis position locking portion 104A is locked onto frame 12A and springs106U, 106L are partially compressed. Please note that during the firstpart of the 45 degree rotation from first position 91 to second position92, tapered surfaces 105AU, 105AL engage with flanges 108AU, 108AL topull the locking portion further into the slot. By guiding lockingportion 104A into place, tapered surfaces 105AU, 105AL also enable anincreased range of acceptance angles for initial alignment of lockingportion 104A and therefore increase the flexibility and ease of use ofcoupling 50 a since it doesn't have to be “dead on” in order to rotate.As coupling 50 a is being rotated from first 91 to second 92 position,teeth 112 AU, 112AL begin to bite into flanges 108AU, 108AL when the endof tapered surfaces 105AU, 105AL is reached. From this point on throughthe rest of the full 90 degree throw, the surfaces of locking portion104A which are in contact with flanges 108AU, 108AL remain relativelyparallel with flanges 108AU, 108AL. Therefore, the force applied bysprings 106U, 106L effectively squeezes coupling 50 a about flanges108AU, 108AL and it is held in a stable position if the wrench isremoved from rotating portion 100. Thus, second position 92, as shown inFIG. 19, is a stable discrete position with coupling 50 a attached onlyto frame 12A. The second frame 12B can now be moved into or out ofposition without knocking coupling 50 a out of position. Unlike someprior art systems which require both PV modules 11A, 11B to be in placeand aligned before a coupling can be connected, the inventive device ofthe first embodiment allows free positioning of modules with coupling 50a connected to one of them in positioning mode. For example, in somecases it may be advantageous to insert couplings into some PV modules 11on the ground before taking them up to a roof to be mounted. In othercases couplings 50 a may be locked onto PV modules 11 at the factoryprior to shipping. Also, when interlocking a free PV module to analready mounted PV module, coupling 50 a may be attached to either thefree PV module or the already mounted PV module. Positioning mode isenabled since locking portion 104B is shaped such that it only begins tolock itself onto frame 12B when coupling 50 a is being rotated fromsecond position 92 to third position 93.

FIGS. 22-24 depict coupling 50 a in third position 93, securely attachedto frames 12A, 12B in locked mode. The process of rotating from secondposition 92 to third position 93 is basically the same as that fromfirst 91 to second 92. A wrench is used to rotate rotating portion 100.Tapered surfaces 105BU, 105BL guide locking portion 104B into slot 26Band teeth 112BU, 112BL begin to bite into flanges 108BU, 108BL when theend of tapered surfaces 105BU, 105BL is reached. Arrival at thirdposition 93 is signaled by locking portion stops 120AU, 120AL contactingupper 122AU and lower 122AL inside surfaces of slot 26A respectively and120BU, 120BL contacting upper 122BU and lower 122BL inside surfaces ofslot 26B respectively. Locking portion stops 120AU, 120AL, 120BU, 120BLprovide a solid, hard stop which prevents rotation of the wrench anyfurther, therefore significantly simplifying the installation procedureand increasing the quality thereof by eliminating the possibility ofover or under-torqued bolts.

The above discussion of the coupling process clearly shows how arotation of coupling 50 a from first position 91 to third position 93causes locking portion 104A to bear against inside surfaces 109AU, 109ALof slot 26A and rotating portion 100 via springs 106U, 106L to bearagainst an opposing frame surface, outside surface 16A. Since springs106U, 106L act to transfer forces from rotating portion 100 to frames12A, 12B, they are also referred to as force transfer portions. Likewiselocking portion 104B bears against inside surfaces 109BU, 109BL of slot26B and rotating portion 100 via springs 106U, 106L bears against anopposing frame surface, outside surface 16B. Thus it is clear thatcoupling 50 a securely interlocks PV modules 11A and 11B together bybearing against opposing surfaces on each frame 12A, 12B upon rotationof rotating portion 100.

Please note that this method of interlocking is quite different frommost prior art systems which interlock adjacent PV modules by means of acoupling that bears against the frame and a strut, a mounting rail, abracket, or other structural member which is sandwiched between oppositeends of the coupling. This basic structural difference enables theforming and mounting of PV arrays 10 without requiring the use ofseparate structural support members (such as strut, mounting rails, andthe like) which attach directly to and span between multiple PV modulesin a formed PV array 10.

First Embodiment—Installation Methods

Referring to FIGS. 7-8 and FIGS. 10-11, the basic steps involved in theforming and mounting of PV array 10 according to the second embodimentof the present invention may be as follows:

Step 1: Secure a first PV module 11 to roof 144R with at least onebracket 132.

Step 2: Interlock a second PV module 11 to the first PV module 11 withat least one parallel coupling 50 a which interlocks the sides of twoadjacent frame members 13 together in parallel.

Step 3: Attach second PV module 11 to roof 144R with at least onebracket 132.

Step 4: Repeat steps 2 and 3 for all remaining PV modules 11 in PV array10, successively interlocking each new PV module 11 to the side of amounted PV module 11 and attaching at least one bracket 132 to eachmodule.

The details of Step 2 above may be as follows: insert coupling 50 a intoslot 26 of the mounted PV module 11, rotate rotating portion 100 tosecond position 92 with a wrench thereby enabling positioning mode, matesecond PV module 11 with coupling 50 a, rotate coupling 50 a to thirdposition 93 thereby enabling locked mode. The wrench is operated fromabove by sliding wrench between the two modules 11 (which may be asclose as approximately ¼″ apart). Alternately coupling 50 a may beplaced on the free module 11 for positioning mode instead of the mountedmodule 11.

The details of Step 3 may be as follows: install bracket flashing ormounting plate, loosely install bracket 132 on mounting plate, attachbracket 132 to PV module 11 at any point along the side where it linesup with required bracket placement, secure bracket 132 to mountingplate. Since there are many types of mounting surfaces, there, of coursenumerous ways that brackets 132 can be installed. Thus, the inventivesystem of the first embodiment provides slot 26 and height adjustablebracket 132 in order to provide maximum flexibility in adapting toalmost any mounting situation.

Parallel couplings 50 a may be used at substantially any point in anyhorizontal 150 or vertical 152 seam between adjacent PV modules. Eachseam 150, 152 may include one, multiple, or no couplings 50 a dependingon the installation requirements. Substantially all brackets 132 may beattached by sliding channel nuts 134 into slots 26 from the end,aligning with bracket 132, and screwing bolt 136 into channel nut 134 tocapture bracket 132.

Final tightening of each coupling 50 a and bracket 132 connection isflexible and does not necessarily coincide with initial placement inarray 10 of that module 11. This flexibility allows PV modules 11 to betemporarily positioned in the array while others are positioned or whilewiring or other installation issues are handled. Since all couplings 50a are capable of being tightened from the top, PV modules 11 can bemoved into locked mode at any time. One skilled in the art willrecognize that the 2-axis nature of the couplings in the embodimentunder discussion means that PV modules 11 can be installed in any orderand in substantially any shape for PV array 10 as long as each new PVmodule 11 is interlocked to a mounted PV module 11, and all new modules11 are added to a mounted module which has a portion of a frame member13 free (not already interlocked to another PV module). It is possible,for example, to mount PV modules in a generally rectangular shape, butthen leave out modules 11 in the middle to avoid vents or otherobstructions. In another example, each row of PV modules 11 may bedisplaced by a specific amount for architectural reasons or to match aroof line.

If a module 11 needs to be removed from the middle of a formed array forservicing, the required steps may be as follows. First, move allcouplings 50 a which are connected to it back into first position 91with a wrench from above thereby enabling sliding mode for each. Thenslide all loosened couplings 50 a over to neighboring modules 11. Insome cases a bracket 132 may prevent sliding in one direction but notboth. Brackets 132 are typically installed with one per module, so thereis normally at least one direction to slide. If two brackets 132 arerequired, then couplings 50 a are not used in between the two brackets132. Next, loosen bolts 136 which connect brackets 132 to frames 12 onthe effected module 11 and lift it straight up and out of array 10(disconnecting wires before moving it too far). In this way anindividual PV module 11 that is installed in the middle of array 10 maybe removed without requiring the removal of the surrounding modules 11,thereby substantially saving time during troubleshooting and maintenanceas compared to prior art systems.

In another embodiment PV modules 11 comprise non-rectangular shapes suchas triangular or hexagonal and the coupling system works in the samemanner as described above. In another embodiment PV modules 11 are smallenough to not require one bracket 132 per module. In this embodimentmultiple modules are interlocked together and then one of the group isattached to roof 144R with bracket 132. In yet another embodiment PVarray 10 is mounted to a ground-mounted rack system instead of roof 144Rwith no change in the basic installation method outlined above exceptthat brackets 132 are attached to the rack instead of roof 144R. Instill another embodiment groups of standard-sized PV modules 11 areinterlocked together via couplings 50 a on the ground and then hoistedto a roof where brackets 132 are used to secure them in place.

First Embodiment—Advantages

The first embodiment of the present invention provides numerousadvantages over prior art systems. Inventive features of the presentapparatus include, but are not limited to the following:

Parallel coupling action—parallel coupling is attachable tosubstantially the whole length of all four sides of a PV module andsecurely locks the outside surfaces of parallel frame members togetherin a side to side arrangement, thereby increasing the structuralperformance of the PV array.

Three mode design—Parallel coupling is shiftable with a wrench intothree modes of operation: positioning mode, sliding mode, and lockedmode. A positive stop is provided when locked mode is reached.

Locking portion—Parallel coupling provides two specially shaped lockingportions which are insertable into slots on the outside surfaces ofadjacent frame members. Locking portions enable discrete positions ofdevice and provide a positive stop for locked position.

Dual bearing action—Parallel coupling interlocks adjacent frame memberstogether by bearing against opposing surfaces on each frame uponrotation of a rotating portion. Locking portion bears against an insidesurface of the slot and the coupling bears against an opposing surface.

Twist-lock action—Parallel coupling provides a rotating portion whichshifts from an unlocked position to a locked position in approximately90 degrees of rotation.

Top accessible—Parallel coupling is accessible from the top even afterPV array has been formed. Coupling can be rotated with a wrench fromabove to shift from locked mode to sliding mode so that coupling can beslid into the slots of neighboring PV modules. In this way a single PVmodule can be removed from the middle of a formed PV array.

One-piece—Parallel coupling is deployable in the field as a one-pieceunit.

Automatic alignment—Parallel coupling forces interlocked PV modules intoalignment along both the x and y axes of PV array. Spacing betweenmodules and height of modules is automatically set upon rotation intolocked mode.

Automatic grounding—Rotation of parallel coupling into locked modecauses integral teeth to bite into frame members thereby enablingreliable x-y matrix grounding for the whole PV array. Only one wire isrequired to ground the whole PV array and the ground connection isuncompromised by the removal of a PV module from the PV array.

Tolerance compensation—Parallel coupling minimizes alignment problemsdue to variable tolerances within PV array via an integral spring.Spring also resists unlocking of mechanism over time and helps tominimize grounding problems by maintaining a known amount of force onground connection.

Multifunction frame—A frame is provided which supports PV laminates andeliminates the need for a strut system which links modules together in aPV array. Each frame member comprises a specially shaped slot whichenables the connection of parallel couplings and mounting brackets tosubstantially the whole length of all four sides of a PV module.Furthermore each slot comprises flanges which enable high-strengthinterlocking and the connection of snap-on options such as cosmeticflashings and debris screens.

The above features provide many useful benefits including, but notlimited to: strutless design, minimal attachment points, accessible yethidden wiring, flexible mounting options, three dimensionaladjustability, rapid formation of PV array, better load distribution,better airflow, more flexible wiring options, low part count, improvedaesthetics due to lower profile and better alignment, and increasedflexibility for orientation (landscape or portrait o.k.).

When removing the strut from a PV mounting system, significantstructural challenges are revealed. We will now discuss in more detailthe structural advantages of the first embodiment relative to prior artstrutless systems.

First, coupling 50 a maximizes structural integrity relative to size byoperating on frame 12 in a direction substantially perpendicular tooutside surface 16 (instead of parallel to it). This fact enables thecost-effective creation of flanges 108AU, 108AL, 108BU, 108BL in frame12 extrusion which provide a thick and very strong surface that coupling50 a utilizes as a wall for holding the ends of locking portions 104A,104B. This arrangement results in a very high pull-out strength ascompared to the press-fit resistance provided by prior art systems. Theflanges 108AU, 108AL, 108BU, 108BL are described as cost-effective sincethey run longitudinally in the same direction that an extrusion processwould run in order to extrude frame members 13 in a typicalmanufacturing process. Creation of equivalent flanges running at 90degrees to flanges 108AU, 108AL, 108BU, 108BL as required by prior artsystems requires additional machining operations.

Second, the major part of the coupling can be located in the gap betweenmodules instead of inside the frame member, thereby reducing therequired size for the frame.

Third, attaching coupling 50 a to outside surface 16 of frame 12 withlocking portions that engage positively inside both the top and bottomframe member flanges 108AU and 108AL, allows coupling 50 a to resistforces that would separate the opposing frame outside surfaces 16,especially in comparison to prior art systems. Furthermore, because itis these separating forces that are the primary forces that we need toovercome with such a coupling, and it intrinsically does this in aneffective manner, it can be designed smaller than prior art solutions,and will therefore involve lower material costs.

Fourth, teeth 112AU, 112AL, 112BU, 112BL enhance the longitudinalholding strength of coupling 50 a since they are circular to facilitatebiting into frame 12 as rotating portion 100 is rotated to lock coupling50 a. These teeth therefore resist being dragged along the longitudinalaxis.

In addition to the structural advantages discussed above, the groundingsystem provided by the first embodiment of the present invention alsohas unique benefits. The system is more reliable than the prior artsince the amount of force supplied to the grounding means is dependanton the stiffness of springs 106U, 106L. Once the correct spring size isdetermined, all couplings will supply a consistent amount of force tothe ground connection and this force will not be dependant on how hard atechnician tightens the coupling.

It follows from the above discussion that the first embodiment of thepresent invention provides significant advantages over prior artsystems. Other objects and advantages of the present invention will alsobe discussed.

Second Embodiment—Structure

FIGS. 25-31 depict a second embodiment of the present invention. Thisembodiment is similar to the first embodiment described above exceptthat it includes minor changes to the framing and coupling systems inorder to lower manufacturing costs and simplify installation.

FIGS. 25-26 present a cross sectional view of two interlocked modules211A, 211B and a perspective view of four interlocked PV modules 211A,211B, 211C, 211D respectively. Slot 26A, 26B is removed from twoopposing frame members 13 yielding a hybrid, strut-like frame 212 withtwo un-slotted frame members 913 and two slotted frame members 213.Un-slotted frame members 913 may be smaller and lighter weight thanslotted frame members 213. In another embodiment un-slotted framemembers 913 are made from a lightweight plastic material and areprimarily used to protect laminate 20 edges (instead of providingstructural support). In another embodiment frame members 913 are notused at all.

Frames 212A, 212B, 212C, 212D each comprise an outside surface 216A,216B, 216C, 216D; an inside surface 217A, 217B, 217C, 217D; a topsurface 214A, 214B, 214C, 214D; and a bottom surface 215A, 215B, 215C,215D (not all surfaces viewable in these drawings). Four interlocked PVmodules 211A, 211B, 211C, 211D are oriented such that slots 226A, 226Bwith openings 227A, 227B parallel each other and slots 226C, 226D withopenings 227C, 227D parallel each other. The two modules 211A, 211Bcomprise slot inside surfaces 209AU, 209AL, 209BU, 209BL (modules 211B,211C comprising like surfaces which are not labeled). Thus, all slottedframe members 213, except those around the perimeter of array 10, may belocated immediately adjacent to other slotted frame members 213, and allun-slotted frame members 913, except those around the perimeter of array10, may be located immediately adjacent other un-slotted frames sides913. The designation PV module 211 refers to any PV module in array 10and the designation 212 refers to any PV module 211 frame in array 10.Likewise a slot 226 refers to any slot 226A, 226B, 226C, 226D withinarray 10.

In order to maintain structural linking in both the x and y directions,as is shown in the first embodiment described above, the secondembodiment of the present invention replaces coupling 50 a with aparallel coupling 50 b in some locations. In other locations a parallelcoupling 50 j is utilized in place of coupling 50 a. In locations wheretwo frame members 13 have been changed to un-slotted frame members 913there are no couplings since there is no slot 26 for couplingconnection. Parallel coupling 50 b is also referred to as a doublecoupling or series-parallel coupling 50 b because it further comprises aseries coupling portion 162 which is utilized to provide a seriescoupling connection to a second pair of adjacent PV modules. Thusparallel coupling 50 b interlocks four PV modules 211A, 211B, 211C, 211Dinstead of two as is typical in prior art systems. A more detaileddescription of the layout of couplings 50 b and 50 j is provided below.All couplings 50 j and 50 b are shown here in horizontal seams 150, butother embodiments provide all couplings 50 j and 50 b in vertical seams152. In still other embodiments frame members 13 are substantiallysimilar on all four sides and therefore couplings 50 j and 50 b arelocated in both the horizontal 150 and vertical seams 152.

FIG. 27 depicts a perspective view of a generally rectangular-shapedparallel coupling 50 b. Coupling 50 b comprises two parallel couplingportions 50 bb and a series coupling portion 162. Parallel couplingportions 50 bb are similar to couplings 50 j (described below) exceptthat they may be shaped slightly differently in order to work well withseries coupling portion 162. For example, in one embodiment parallelcoupling portions 50 bb are similar to couplings 50 j except that theyfurther comprise retainer portions which enable them to be movablysecured to series coupling portion 162, thereby allowing coupling 50 bto be deployed as a one-piece unit in the field. In the presentembodiment under discussion coupling portions 50 bb are the same ascouplings 50 j thus allowing coupling 50 b to be a three piece unitcomprising two parallel coupling portions 50 bb and one series couplingportion 162. In another embodiment more than two coupling portions 50 bbare utilized for additional strength. In still another embodiment seriescoupling portion 162 comprises retainer portions which enable parallelcoupling portions 50 bb to be movably secured to series coupling portion162, thereby resulting in a one-piece coupling 50 b.

Referring to FIGS. 25-27, series coupling portion 162 comprises a firstside 164 adapted to mate with outside surfaces 216A, 216C of the fourinterlocked PV modules 211A, 211B, 211C, 211D. First side 164 comprisesthree male protrusions which mate with frames 212A, 212C to increase thestrength of frames 212A, 212C at the point of coupling. Male protrusion165 is adapted for insertion into auxiliary slots 224A, 224C in frames212A, 212C and may be tapered slightly to insure a snug fit ismaintained despite tolerance issues. Male protrusion 166 is adapted forinsertion into slots 226A, 226C in frames 212A, 212C and comprises teeth168U, 168L which bite into frames 212A, 212C to insure solid electricalground contact and to enhance the structural connection between PVmodules 211A, 211C. Male protrusion 166 may be tapered. Male protrusion167 is adapted to slide just beneath frames 212A, 212C and may betapered as well. In other embodiments male protrusions 165, 166, 167 maynot be tapered. Series coupling portion 162 further comprises at leasttwo slots or holes 170A, 170B which allow insertion of parallel couplingportions 50 bb as discussed below and a second side 172 which faces awayfrom PV modules 211A, 211C when series coupling portion 162 isinstalled. In another embodiment teeth 168U, 168L are replaced by teethon a different surface of series coupling portion 162 or a differentportion of coupling 50 b. In other embodiments series coupling portion162 has various numbers of male protrusions. In still another embodimentthere are no male protrusions on series coupling portion 162. Wecontemplate making series coupling portion 162 in a length ofapproximately 3-12″ and out of a rigid material such as aluminum orsteel, though other materials and lengths are possible.

FIG. 28 shows a perspective view of parallel coupling 50 j whichcomprises all of the same portions as coupling 50 a except thefollowing. First, shaft portion 102A, designated here as 232A, has beenextended by approximately the width of bracket 132. Second, rotatingportion 100 has been replaced by rotating portion 200 comprising foursprings 236A, 236B, 236C, 236D, (not all viewable here), two for eachside of coupling 50 j oriented approximately 180 degrees apart. Andthird, spring bores 110U, 110L have been replaced by spring bores 240A,240B, 240C, 240D to correspond with new springs 236A, 236B, 236C, 236D.Coupling 50 j further comprises locking portions 204A, 204B whichfunction the same as locking portions 104A, 104B. All remaining portionsof coupling 50 j are the same as coupling 50 a and are thus notspecifically designated here. Parallel coupling portion 50 bb in thissecond embodiment is the same as coupling 50 j and thus also referencesthe same designations.

FIG. 29 shows a perspective view of height adjustable bracket 132 andparallel coupling 50 j. Another advantage of the second embodiment ofthe present invention is that extended shaft portion 232A allowscoupling 50 j to perform a dual function of interlocking adjacent PVmodules together as discussed above while also attaching bracket 132 toPV module 11. This feature substantially reduces installation time whencompared to prior art systems that require the tightening of separatefasteners for couplings and brackets. One skilled in the art will alsorecognize that vertical adjustment slot 140 in bracket 132 isapproximately perpendicular to slot 26A, 26B, and that springs 236A,236B, 236C, 236D are oriented so that in first position 91 all foursprings are free and uncompressed in the same way as coupling 50 a. Manyother spring variations are possible within the scope of the presentinvention.

FIG. 30 provides a cross-section showing two adjacent PV modules 212A,212B which are interconnected with coupling 50 j. Coupling 50 j is shownin first position 91 as discussed above. When rotated approximately 90degrees, coupling 50 j interlocks frames 212A and 212B together andsimultaneously compresses bracket 132 against frame 212A. Thus, channelnut 134 and channel bolt 136 are no longer needed.

Second Embodiment—Operation

FIG. 31 is the same as FIG. 11 except that PV array 10 utilizes theframing and coupling system of the second embodiment. Brackets 132 areshown in the same locations except now they are connected to frames212A, 212B, 212C, 212D via couplings 50 j, thereby reducing total partcount and installation time required for PV array 10. Series-parallelcouplings 50 b bridge the corner points where the four corners of PVmodules 211A, 211B, 211C, 211D meet. For example, a coupling 50 b isshown bridging a corner point 295 where four PV modules 211A, 211B,211C, 211D meet. Parallel coupling portions 50 bb interlock modules211A, 211B and 211C, 211D while series coupling portion 162 interlocksmodules 211B, 211D and 211A, 211C. Please note that a second seriescoupling portion between 211A, 211C is possible but not required sinceparallel coupling portions 50 bb lock frame 212A to frame 212B and frame212C to frame 212D along with series coupling portion 162.

Thus, the two axis parallel interlock support system 160 from the firstembodiment is replaced by a single axis parallel interlock supportsystem 260 which may run along the x-axis or y-axis. As shown in FIG.31, parallel coupling portions 50 bb and parallel couplings 50 j lockadjacent frame members 213 side to side in parallel which createsvertical rows of paired frame members 213 along the y-axis. Seriescoupling portions 162 interlock frame members 213 longitudinally alongthe x-axis, thereby connecting the vertical rows and increasing theoverall strength of the system. Series coupling portion 162 is locatedbetween rotating portion 100 and outside surface of frames 216. Andsince parallel coupling portion 50 bb is rotatable relative to seriescoupling portion 162, a rotation of rotating portion 100 firmlycompresses series coupling portion 162 into frames 212A, 212C. Thisaction serves to substantially increase the strength of frames 212A,212C relative to a z-axis load (such as wind) in the region of coupling50 b since z-axis loads are distributed longitudinally down frames 212A,212C. While some prior art couplings do also provide increased z-axisstrength due this same effect, series coupling portion 162 may besubstantially stronger for the following reasons: (a) since seriescoupling portion 162 is not fully contained within a slot or internalcavity of frames 212A, 212C, it is able to be much taller in thez-direction thereby increasing strength; (b) coupling portion 162 issecured to frames 212A, 212C by a compressive force about a portion offrames 212A, 212C which increases strength instead of a tensile forcewhich tends to deform the frame and decrease strength; (c) couplingportion 162 comprises upper 165 and lower 167 male protrusions whichtend to prevent deformation of frames 212A, 212C under load since theyprevent widening of opening 227A as seen in FIG. 25; and (d) couplingportion 162 has no fixed center point and therefore may be slid in slots226A, 226C to match up with high load areas.

Accordingly, a rotation of parallel coupling portion 50 bb from firstposition 91 to third position 93 causes locking portion 204A to bearagainst inside surfaces 209AU, 209AL of slot 226A and rotating portion200 via springs 236A, 236C to bear against series coupling portion 162which in turn bears against an opposing frame surface, outside surface216A. In this case the bearing action of rotating portion 200 istransferred through springs 236A, 236C and series coupling portion 162to frame 212A. Therefore springs 236A, 236C and series coupling portion162 are also referred to as force transfer portions. Since there is noseries coupling portion 162 between rotating portion 200 and frame 212B,this portion of the coupling process proceeds the same as discussedabove for module 12B. That is, locking portion 204B bears against insidesurfaces 209BU, 209BL of slot 226B and rotating portion 100 via springs236B, 236D bears against an opposing frame surface, outside surface216B. Thus, PV frames 212A and 212B are locked to coupling 50 b viarotation of rotating portion 200 from first position 91 to thirdposition 93. The other half of coupling 50 b operates in the same way tolock frames 212C and 212D to coupling 50 b. Thus it is clear thatcoupling 50 b securely interlocks PV modules 211A, 211B, 211C, and 211Dtogether by bearing against opposing surfaces on each frame 212A, 212B,212C, 212D upon rotation of rotating portions 200. In other embodimentsdevices which are removable from a mounted PV module 211 along withcoupling 50 b, such as washers, pressure distribution plates, andsprings, are placed between coupling 50 b and frame 212. In these casessuch devices are sometimes referred to as force transfer portions andare considered to be part of coupling 50 b in the same way that seriescoupling portion is so incorporated. On the other hand, brackets andstruts which span between PV modules 211 and/or are attached to amounting surface are not considered to be a part of coupling 50 b sincethey are not removable with coupling 50 b.

As shown in FIG. 30, the second embodiment of the present inventionprovides a means for reducing parts and labor costs by combining thefunction of attaching bracket 132 with the function of interlocking twoadjacent PV modules 211A, 211B. Thus, the installation of PV array nowhas one less step. To our knowledge there are no prior art systems whichteach a combined functionality coupling which can both couple the sidesof two adjacent PV modules together in parallel and simultaneouslysecure a height adjustable bracket to the side of frame 212A.

The basic steps involved in the forming and mounting of PV array 10according to the second embodiment of the present invention may be asfollows:

Step 1: Secure a first PV module 211 to a mounting surface 144 with atleast one bracket 132.

Step 2: Interlock a second PV module 211 to the first PV module 211 withat least one parallel coupling 50 b or 50 j which interlocks the sidesof two adjacent frame members together in parallel.

Step 3: Attach second PV module 211 to mounting surface 144 with atleast one bracket 132.

Step 4: Repeat steps 2 and 3 for all remaining PV modules 211 in PVarray 10, successively interlocking each new PV module 211 to the sideof a mounted PV module 211 and attaching at least one bracket 132 toeach module.

Parallel couplings 50 b may be used at substantially all corner points295 where four PV modules 211 meet. Substantially all brackets which aremounted in the seams between PV modules 211 may be attached viacouplings 50 j. Final tightening of each coupling 50 b, 50 j and bracket132 connection is flexible and does not necessarily coincide withinitial placement in array 10 of that module 211. This flexibilityallows PV modules 211 to be temporarily positioned in the array whileothers are positioned or while wiring or other installation issues arehandled. Since all couplings 50 b and 50 j are capable of beingtightened from the top, PV modules 211 can be moved into locked mode atany time. One skilled in the art will recognize that the 2-axis natureof the couplings in the embodiment under discussion means that PVmodules 211 can be installed in any order and in substantially any shapefor PV array 10 as long as each new PV module 211 is interlocked to amounted PV module 211, and all new modules 211 are added to a mountedmodule which has a portion of a frame member 213 free (not alreadyinterlocked to another PV module). Stepped arrays as discussed above arenot possible when using couplings 50 b.

In another embodiment which is similar to the first embodiment discussedabove, couplings 50 j replace couplings 50 a thereby enabling thecapture of brackets 132 with couplings 50 j, while also retaining thebenefits of an all-parallel coupling installation as discussed.

Third Embodiment

FIGS. 32-34 depict a third embodiment of the present invention. Thisembodiment is similar to the first embodiment described above exceptthat the orientation of the coupling action of coupling 50 a has beenaltered and a retaining element has been added. Instead of bearingagainst vertically oriented opposing surfaces on frame 12, a parallelcoupling 50 c is provided to bear against horizontally oriented opposingsurfaces on frame 12.

FIG. 32 shows a perspective view of parallel coupling 50 c which hasbeen installed into slots 26A, 26B of two adjacent PV modules 11A, 11Bbut not fully tightened down. Frames 12A, 12B have been cut away so thatcoupling 50 c shows in this view. FIG. 33 provides an exploded view ofthe two sides of a retainer portion 354L, 354R. FIG. 34 provides across-section view cut through two adjacent PV modules 11A, 11B whichare coupled together with parallel coupling 50 c. The cross section iscut partially through coupling 50 c as indicated.

Referring to FIGS. 32-34, coupling 50 c comprises retainer portion 354which holds a locking portion 304 and a nut portion 306 via positiontabs 362. Locking portion 304 may comprise a first side 304A for lockingwith frame 12A and a second side 304B for locking with frame 12B. Nutportion 306 may comprise a first side 306A for securing to frame 12A anda second side 306B for securing to frame 12B. Retainer portion 354 maycomprise two substantially identical halves 356L, 356R which matetogether via male and female arm pairs 358LM, 358RF and 358LF, 358RM.Two halves 356L, 356R capture locking portion 304 and nut portion 306and hold them in position as coupling 50 c is inserted into slots 26A,26B. During insertion, snap-lock portions 360LA, 360LB, 360RA, 360RBflex downward then snap back up into position once inserted past flanges108AU, 108BU. We contemplate making retainer portion 354 out of aplastic material, though many other semi-flexible materials are alsosuitable. A bolt or threaded rotating portion 300 comprises a head 352which accepts a tool from above and is used to tighten and loosencoupling 50 c about frames 12A, 12B. Locking portion 304 comprises ahole for rotating portion 300 which is larger than the outside diameterof rotating portion 300 and is not threaded. Nut portion 306 is drilledand tapped for the threads on rotating portion 300 and comprises teeth364 for biting into frames 12A, 12B when coupling 50 c is tightened,thereby providing electrical ground continuity between modules 11A, 11Band enhancing the structural connection of coupling 50 c. We contemplatemaking locking portion 304, and nut portion 306 out of a rigid materialsuch as aluminum or steel, though other materials are also suitable.

Operation of the apparatus of the third embodiment is similar to thefirst embodiment except for the operation of coupling 50 c. Coupling 50c may be pre-assembled in a factory by mating halves 356L, 356R aboutlocking portion 304 and nut portion 306 so that coupling 50 c may bedeployed as a one-piece unit ready for installation in the field. Toinstall, coupling 50 c is inserted at substantially any point along slot26A in PV module 11A. Coupling 50 c is inserted with snap-lock portions360LA, 360RA pointing towards opening 27A in slot 26A and with adirection of travel which is substantially parallel with the plane oflaminate 20A and substantially perpendicular to the length of slot 26A.Coupling 50 c is inserted until snap-lock portions 360LA, 360RA clearflange 108AU and snap into place. Coupling 50 c is now in positioningmode and ready to be coupled to PV module 11B. With coupling 50 c beingheld in place by retainer portion 354, PV modules 11A and 11B are freeto be moved independently from each other. Thus, this embodimentprovides the same independent movement capability in positioning mode asdiscussed above for the first embodiment, but coupling 50 c is held inposition during this phase by retainer portion 354 instead of lockingportions 104A, 104B. To complete the coupling operation, coupling 50 cis inserted into slot 26B until it snaps in place as described above.Then a driver is used to engage rotating portion head 352 and rotaterotating portion 300 which pulls nut portion 306 toward slots 26A, 26Band pushes locking portion 304 away from slots 26A, 26B.

More specifically, rotation of rotating portion 300 causes lockingportion 304 and nut portion 306 to move closer together which in turncauses locking portion 304 to bear against inside surfaces 309AL, 309BLof slots 26A, 26B and nut portion 306 to bear against opposing surfaces,bottom surfaces 15A, 15B of frames 12A, 12B. Thus it is clear thatcoupling 50 c securely interlocks PV modules 11A and 11B together bybearing against opposing surfaces on each frame 12A, 12B upon rotationof rotating portion 300. As locking portion 304 and nut portion 300tighten about frames 12A, 12B position tabs 362 bend or break since theyare overpowered by the force delivered by the driver to rotating portion300. Once rotating portion 300 is tight, coupling 50 c is now in lockedmode. Sliding mode can be accessed at any time by loosening rotatingportion 300, which is still accessible from the top even after array 10has been formed. As with the first embodiment, sliding mode allowssliding of coupling 50 c over to a neighboring seam 150 or 152 so that amodule can be removed from the middle of a formed PV array 10.

In other embodiments a surface area of contact between locking portion304 and frames 12A, 12B is increased by widening or removing altogetherflanges 108AL, 108BL. Another embodiment extends locking portion 304 andnut portion 306 with series coupling portions so that they reach over tothe next pair of modules, thereby creating a four module couplingsimilar the second embodiment above. In another embodiment lockingportion 304 comprises a spring element for bearing against an insidesurface of slot 226. In yet another embodiment retainer portion 354 isshaped differently so that it comprises spring elements for the top andbottom flanges.

Fourth Embodiment

FIGS. 35-38 depict a fourth embodiment of the present invention. Thisembodiment is similar to the second embodiment as described above exceptthat locking portions 204A, 204B and rotating portions 200 have beenaltered slightly.

FIG. 35 depicts a perspective view of a parallel coupling 50 d installedin two adjacent PV modules 211A, 211B and FIG. 36 presents a perspectiveview of coupling 50 d with a rotating portion 400CD which has been slidover to the right (see below for explanation). FIG. 37 provides a crosssection cut through a seam between four PV modules 211A, 211B, 211C,211D which have been interlocked together with coupling 50 d, and FIG.38 depicts a perspective view of four interlocked PV modules 211A, 211B,211C, 211D. As is consistent with the present invention, parallelcoupling 50 d comprises locking portions 404AC, 404BD and rotatingportions 400AB, 400CD which serve to compress frames 212 upon movementof coupling 50 d into locked mode. Locking portions 404AC, 404BD differfrom locking portions 104A, 104B in that they have been elongated withseries coupling portions 462 to bridge between the two pairs of PVmodules 211A, 211C and 211B, 211D; thus enabling coupling 50 d tointerlock four adjacent PV modules in a similar manner to the secondembodiment except without requiring a separate series coupling portion162. Coupling 50 d is deployable in the field as a one-piece unit whichis capable of interlocking four PV modules 211A, 211B, 211C, 211Dtogether. Instead of utilizing two parallel coupling portions 50 bb plusseries coupling portion 162 as discussed for the second embodiment, thisembodiment essentially allows two coupling members to share two lockingportions 404AC, 404BD thereby creating a “double coupling” device.

Since locking portions 404AC, 404BD can no longer rotate within slots26A, 26B, 26C, 26D to tighten coupling 50 d, threaded shaft portions402A, 402B, 402C, 402D (not all visible) replace shaft portions 232A,232B and thread into threaded holes 490A, 490B, 490C, 490D (not allvisible) in locking portions 404AC, 404BD. Opposite ends of shaftportions 402A, 402B and 402C, 402D are provided with opposite handedthreads so that rotation of shaft portions 402A, 402B, 402C, 402D causeslocking portions 404AC, 404BD to move horizontally in oppositedirections from each other according to the arrow shown in FIG. 36.Rotating portions 400AB, 400CD replace rotating portions 100 andfunction the same except that rotating portions 400AB, 400CD aredecoupled from shaft portions 402A, 402B, 402C, 402D allowing them tomove horizontally independently from shaft portions 402A, 402B, 402C,402D according to the arrow shown on FIG. 36. Rotating portions 400AB,400CD, however, cannot rotate independently from their respective shaftportions 402A, 402B and 402C, 402D as they are provided with hexagonalbores 492AB, 492CD to match hexagonal portions 494AB, 494CD which may berigidly connected or formed from shaft portions 402A, 402B and 402C,402D respectively. In other embodiments hexagonal parts are providedwith other shapes to achieve the same functionality.

Referring specifically to FIG. 37, it is evident that a rotation ofrotating portion 400AB with a wrench in a first direction causes lockingportions 404AC, 404BD to pull frames 212A, 212B towards each other.Since rotating portion 400AB is slidable, it slides along hexagonalshaft portion 494AB until it is contacting both outside surfaces 216A,216B of PV modules 211A, 211B. Additional rotation in the firstdirection after both frames 212A, 212B have contacted rotating portion400AB causes locking portion 404AC to bear against inside surfaces209AU, 209AL of slot 226A and rotating portion 400AB to bear against anopposing frame surface, outside surface 216A. Likewise, rotation ofrotating portion 400AB causes locking portion 404BD to bear againstinside surfaces 209BU, 209BL of slot 226B and rotating portion 400AB tobear against an opposing frame surface, outside surface 216B. Thus, PVframes 212A and 212B are locked to coupling 50 d via rotation ofrotating portion 400AB. The other half of coupling 50 d operates in thesame way to lock frames 212C and 212D to coupling 50 d. Thus it is clearthat coupling 50 d securely interlocks PV modules 211A, 211B, 211C, and211D together by bearing against opposing surfaces on each frame 212A,212B, 212C, 212D upon rotation of rotating portions 400AB, 400CD.

Once both rotating portions 400AB and 400CD have been rotated into theirfully tightened positions, coupling 50 d is in locked mode as discussedearlier. Rotation of rotating portion 400AB in a second direction whichis opposite the first direction decouples PV modules 211A and 211B. Ifboth rotating portions 400AB and 400CD are rotated so as to decouple PVmodules 211A, 211B and 211C, 211D respectively, then coupling 50 d isshifted into sliding mode and is therefore free to slide completely overinto the slots of either PV modules 211A, 211B or 211C, 211D.

FIGS. 35 and 37 also reveal raised portions or teeth 496AC and 496BD onlocking portions 404AC, 404BD which bite into frames 212A, 212B, 212C,212D when coupling 50 d is tightened thereby providing a reliableelectrical ground connection between all four PV modules 211A, 211B,211C, 211D and enhancing the structural properties of coupling 50 d.These drawings also show optional retainer portions 454AC, 454BD on thetop and bottom of locking portions 404AC, 404BD. Retainer portions454AC, 454BD may comprise a flexible material which allows insertion ofcoupling 50 d into a pair of slots 226A, 226B from the end but preventscoupling 50 d from falling back out on its own or from sliding aroundprior to being shifted into locked mode. Another embodiment is the sameas the fourth embodiment except only comprises one rotating portion andis approximately half as long. This embodiment functions the same but isoptimized to interlock two PV modules 211 together instead of four.

The fourth embodiment provides several advantages relative to some ofthe other embodiments discussed herein. The sliding capability ofrotating portion eliminates the need for springs 236A, 236B, 236C, 236D;incorporation of a series coupling portion 462 into locking portions404AC, 404BD eliminates the need for series coupling portion 162; andmanufacturing costs may be reduced. However, series coupling portion 462is not as strong as series coupling portion 162 since it must becontained within slots 226A, 226B.

Additional Embodiments

FIGS. 39-40 depict a perspective view and a cross section cut betweentwo interlocked PV modules 211A, 211B respectively for an alternateembodiment which is similar to the fourth embodiment as shown in FIGS.35-38. This embodiment, which helps to lower manufacturing costs,provides a parallel coupling 50 e in which rotating portions 400AB,400CD have been eliminated in favor of a plurality of rotating portions500. This arrangement enables the attachment of coupling 50 e to frames212 via a bearing action against two opposing surfaces which are bothinside of slot 226 instead of one internal and one external as shown forthe fourth embodiment. Locking portions 504AC, 504BD are almost the sameas before, but now retainer portions 454AC, 454BD and teeth 496AC, 496BDhave been eliminated. Locking portions 504AC, 504BD are rigidly joinedtogether by y-axis spacer block 574 with x-axis spacer screw 576. Spacerscrew 576 is in place as shown during initial installation so that eachmodule can be slid up to screw 576. But if a module needs to be removedfrom array 10 after compete installation, spacer screw 576 is removedand coupling 50 e is slid completely over to the next horizontal seam150. Locking portions 504AC, 504BD also comprise series couplingportions 562 as before. Rotating portions 500 comprise shaft portions502 which may be threaded and further provided with a cupped end forbiting into frames 212 to insure reliable electrical ground and toenhance the structural properties of coupling 50 e. Thus, rotatingportions 500 comprise a portion which resides inside of slots 226 and aportion which resides outside of frames 212. The external portion ofrotating portions 500 may also comprise a hexagonal or other shaped headportion 503 which allows rotation from above similar to rotatingportions 400AB, 400CD.

Referring to FIG. 40 and the coupling process between PV modules 211A,211B, a rotation of rotating portions 500 causes them to bear againstinside surfaces 507A, 507B of slots 226A, 226B thereby forcing lockingportions 504AC, 504BD to bear against opposing inside surfaces 509AU,509AL, 509BU, 509BL, thereby securely coupling the sides of adjacent PVmodules 211A and 211B together. Since coupling 50 e, like coupling 50 d,is designed to connect four adjacent PV modules together, one skilled inthe art will recognize that the coupling of modules 212C and 212Dutilizes the same process as just discussed for PV modules 212A and212B. Thus it is clear that coupling 50 e securely interlocks PV modules211A, 211B, 211C, and 211D together by bearing against opposing surfaceson each frame 212A, 212B, 212C, 212D upon rotation of rotating portions500.

In another embodiment similar to the previous the half of lockingportions 504AC, 504BD that interlock PV modules 211C, 211D together iseliminated along with series coupling portion 562. This leaves atwo-module parallel coupling which is possibly suitable for use in PVarray 10 along with couplings 50 e (like at the ends of rows). Inanother embodiment a coupling is formed out of a single locking portion504AC along with associated rotating portions 500 from coupling 50 e.While this embodiment is similar to prior art series couplings, itdiffers significantly in that the coupling action results from a bearingon two opposing surfaces of slot 226 (for increased strength).Furthermore, there is no press-fit action and the grounding is providedby rotating portions 500. Another embodiment is similar to theembodiment of FIGS. 39-40 except that spacer block 574 is slidably heldbetween locking portions 504AC, 504BD via pins between locking portionsand is taller than slot opening 227A. This variation works similarly tothe fourth embodiment except that instead of rotating portions slidingto set the spacing between modules, it is the spacer block which slides.In still another embodiment multiple spacer blocks are utilized.

FIGS. 41-42 depict a cross section cut between two interlocked PVmodules 11A, 11B and a perspective view respectively for an alternateembodiment which is similar to the first embodiment as shown in FIGS.1-24, but may lower manufacturing costs. This embodiment provides acoupling 50 f with locking portions 604A, 604B which are threaded intorotating portion 600 via shaft portions 602A, 602B instead of beingrigidly connected thereto. Rotating portion 600 has also been trimmeddown in size so that coupling 50 f can not only be slid into the slots26A, 26B of a neighboring pair of PV modules (in sliding mode), but sothat it can also “turn the corner” and move from an x-axis directionslot into a y-axis direction slot and vice versa. This feature enablesremoval of a PV module even when the slots within the PV array are notaligned in one direction. This may occur in some cases by accident, orin other cases due to tolerance issues, or for architectural reasons.Springs 606U, 606L on rotating portion 600 are smaller than before butfunction the same. Shaft portions 602A, 602B are provided with oppositethreading so that rotation of rotating portion 600 causes lockingportion 604A to bear against inside surface 109AU, 109AL of slot 26A androtating portion 600 to bear against an opposing surface, outsidesurface 16A of frame 12A. Likewise, locking portion 604B bears againstinside surface 109BU, 109BL of slot 26B and rotating portion 600 bearsagainst an opposing surface, outside surface 16B of frame 12B. Thus itis clear that coupling 50 f securely interlocks PV modules 11A, 11Btogether by bearing against opposing surfaces on each frame 12A, 12Bupon rotation of rotating portion 600.

In another embodiment similar to the previous one discussed, lockingportion 604A and shaft portion 602A is replaced by locking portion 104Aand shaft 102A from the first embodiment.

FIGS. 43-44 depict a perspective view and a cross section cut betweentwo interlocked PV modules 11A, 11B respectively for an alternateembodiment which is similar to the third embodiment as shown in FIGS.32-34. This embodiment lowers the amount of installation time requiredby replacing rotating portion 300 with a shaft 750 and cams 780A, 780Bon a parallel coupling 50 g. Cams 780A, 780B are rigidly connected torotating portion 700 which is rotatable about axle 788 with a wrenchfrom above. Shaft 750 comprises a flat, narrow portion 774 with a hole(not visible) that shaft 788 runs through, a medium diameter portion775, a larger diameter portion 776, and a head portion 752. A washerportion 706 with sides 706A, 706B is positioned on shaft portion 776 andcomprises a bore (not viewable) larger than shaft portion 776 butsmaller than a diameter of head portion 752. A locking portion 704 withsides 704A, 704B is positioned on shaft portion 775 and comprises a bore(not viewable) larger than shaft portion 775 but smaller than shaftportion 776. Locking portion 704 comprises thicker portions 785A, 785Band is pushed down onto ledge 788 by retainer springs 756A, 756B (indirection of arrow) when not installed.

To operate, cams 780A, 780B are rotated so that they are not touchinglocking portion 704. Then coupling 50 g is snapped onto frame 12A. Wecontemplate making springs 756A, 756B out of a flexible material such asrubber or similar so that they allow locking portion 704 and washerportion 706 to open up when pushed onto frame 12A. Thicker portions785A, 785B in conjunction with springs 756A, 756B prevent coupling fromfalling off, thus enabling positioning mode. Frame 12B and coupling 50 gare wedded in the same fashion. Once coupling 50 g is loosely positionedonto both frames 12A, 12B, then a wrench is used to rotate rotatingportion 700 which in turn rotates cams 780A, 780B, which force lockingportion 704 and washer portion 706 to move toward each other. Thismovement causes locking portion 704 to bear against inside surfaces309AL, 309BL of slots 26A, 26B and washer portion 706 to bear againstopposing surfaces, bottom surfaces 15A, 15B of frames 12A, 12B. Thus itis clear that coupling 50 g securely interlocks PV modules 11A, 11Btogether by bearing against opposing surfaces on each frame 12A, 12Bupon rotation of rotating portion 700. Raised teeth 764 bite into frames12A, 12B upon tightening, thereby ensuring ground contact and enhancingstructural properties as described earlier. In another embodimentsprings 756A, 756B comprise a resting position as depicted and thereforedo not push locking portion down onto ledge 788 when not installed.Another embodiment provides a cam shape which sets the straight-upposition as free, then rotating one direction moves to positioning modeand rotating the other way enables locked mode. And another embodimentprovides a handle connected to rotating portion 700.

FIGS. 45-46 depict a perspective view and a cross section cut betweentwo interlocked PV modules 11A, 11B respectively for an alternateembodiment which is similar to the third embodiment as shown in FIGS.32-34. This embodiment may provide a lower manufacturing cost byreplacing retainer portion 354 with retainer springs 856A, 856B betweena locking portion 804 and a nut portion 806. Similar to the previousembodiment, a coupling 50 h comprises retainer springs 856A, 856B whichpull a locking portion 804 with sides 804A, 804B down onto a ledge 888when not installed (in direction of arrow). Coupling 50 h is snappedonto frame 12A and temporarily held in place during positioning mode bysprings 856A, 856B and thicker portions 885A, 885B of locking portion804. Thicker portions 885A, 885B may also be sized to provide a positiveengagement for lateral loads. Rotation of rotating portion 300 causesthe coupling to shift to locked mode as described for the thirdembodiment. Another variation of this embodiment provides springs 856A,856B which are in their resting state as shown so that ledge 888 is notneeded. Yet another variation replaces thicker portions 885A, 885B withteeth that interlock with frame and another provides grounding spikes onlocking portion 804.

FIGS. 47-48 depict a cross section cut between two interlocked PVmodules 11A, 11B and a perspective view respectively for an alternateembodiment which is similar to the first embodiment as shown in FIGS.1-24. The primary distinction of the present embodiment, which describesa coupling 50 i, is that locking portions 104A, 104B have been replacedby pairs of locking portions 904AU, 904AL and 904BU, 904BL respectively.The paired locking portions 904AU, 904AL and 904BU, 904BL are providedwith ridged camming surfaces 982AU, 982AL, 982BU, 982BL which areadapted to bear against inside surfaces 909AU, 909AL, 909BU, 909BL whena rotating portion 900 is rotated. Rotating portion 900 is rigidlyconnected to locking portions 904AU, 904AL, 904BU, 904BL via a pair ofshafts (not visible) which run through retainer portions 954A, 954B.Retainer portions 954A, 954B may be made of a flexible material so thatinsertion of retainer portions 954A, 954B into slots 26A, 26B deforms orbends retainer portion enabling positioning mode. Ridges on ridgedcamming surfaces 982AU, 982AL, 982BU, 982BL bite into frames 12A, 12Bupon rotation thereby securing ground contact and increasing thestrength of coupling 50 i. Locking portions 904AU, 904AL, 904BU, 904BLcomprise flattened portions 980A, 980B which enable insertion whenproperly aligned with slots 26A, 26B since they reduce the overall widthto less than opening 27A, 27B. Thus, insertion of locking portions904AU, 904AL, 904BU, 904BL into slots 26A, 26B followed by a rotation ofnut portion 900 causes locking portions 904AU, 904AL, 904BU, 904BL tobear against opposing surfaces 909AU, 909AL, 909BU, 909BL, therebysecurely coupling the sides of adjacent PV modules 11A and 11B together.In another embodiment locking portions 904AU, 904AL, 904BU, 904BL arerotated 90 degrees from the orientation shown so that rotation ofrotating portion 900 causes a camming action between the back of slot 26and inside surfaces 109AL, 109AU. In another embodiment retainerportions 954A, 954B are eliminated in favor of an offset cam arrangementsimilar to the first embodiment where one cam is insertable in bothfirst position 91 and second position 92.

FIGS. 49-50 depict an embodiment which is similar to the secondembodiment discussed above except that a spacer block 274 has beenadded. FIG. 49 is the same as 26 except spacer block 274 is showninstalled onto series coupling portion 162 via a slot 276 on the bottomside. FIG. 50 provides a perspective view of spacer block 274 whichfurther reveals slot 276 and a bottom mounted wire clip 285 for securingPV module 11 output wires 22neg, 22pos. Securing wiring in this way is asubstantial improvement over prior systems since wire clip 285 providesa means of preventing wires from unsightly and unsafe drooping onto roofsurfaces. Furthermore, the horizontal seam 150 between PV modules 211A,211B and 211C, 211D is set for this embodiment slightly wider than thewidth of wiring plugs 24neg, 24pos; therefore troubleshooting andmaintenance of PV array 10 wiring systems is greatly simplified sinceone can easily snap spacer block 274 up and off from the top and pullwires 22neg, 22pos right up through seam 150 for inspection and repair.No decoupling of PV modules 11A, 11B is required in order to maintainthe wiring system between them. In another embodiment a wire clipcomprises a spring clip which snaps into slot 26A thereby allowing thestrapping of wires substantially along the whole length of frame 26A. Instill another embodiment a hinged wire clip 285 snaps into slot 26A andswings underneath module 11 to hide it, then back up into the gapbetween modules 11 to allow access.

FIGS. 51-52 depict an embodiment of the present invention which issimilar to the second embodiment discussed above except that PV array 10is installed on an open canopy structure 144C instead of roof 144R.Installation on a different mounting surface 144 for PV array 10requires minor changes to brackets 132 and series coupling portions 162as will be discussed below.

FIGS. 51 and 52 depict a perspective view and a side view respectivelyof PV array 10 installed on canopy structure 144C. Canopy 144C comprisespurlins 180 which are supported by girders 182 which in turn aresupported by vertical columns 184. We contemplate vertical columns 184of approximately the same height for this embodiment in order todemonstrate that substantially any tilt angle (from flat to vertical)for PV array 10 is suitable. For example, many prior art systems requirea specific slope to a PV array in order for the interlocking or mountingsystems to function properly, but the coupling and framing systemsdescribed herein do not place any such limitations on PV array 10. PVarray 10, as shown in FIG. 51, comprises a total of sixteen PV moduleswhich are mechanically interlocked in groups of four with couplings 50 bin the same manner described in FIGS. 25-28. Use of a different mountingsurface 144 in this embodiment requires slight changes to the bracketsand the layout of series coupling portions 162. The detail in FIG. 51shows a double bracket 186 which is utilized to directly connect twoframes 212 to purlins 180 in the central vertical seam 152 where thegroups of four PV modules 211A, 211B, 211C, 211D come together. Doublebracket 186 comprises vertical portions 187L, 187R with verticaladjustment slots 188 for connecting to frames 212 in the same way asbracket 132 only this bracket connects to two adjacent PV modules 211.Each horizontal row along the central vertical seam 152 comprises onedouble bracket 186, but not all are visible here. Double bracket 186further comprises U-bolt slots 190L, 190R (not all visible), U-bolt 192,nut and washer 193 for securing double bracket 186 to purlin 180, and aseries coupling portion 962. PV modules 211 are secured to the other twopurlins by means of a bracket 132U which is similar to double bracket186 except that there is only one vertical portion 187 since this is thelast row of PV modules 211.

Regarding the present embodiment under discussion, it is also importantto note that there are no strut or PV frame support members required aswould be the case for most prior art systems. For example, PV array 10as shown in FIG. 51 would normally require an additional layer of PVframe support members 131PA between purlins 180 and PV frames 212 or asan alternative some prior art systems allow increasing the number ofpurlins shown to 8 (two per row) instead of adding another layer ofstructural support (thus the purlins become the PV frame supportmembers). The inventive system of this embodiment however creates aparallel interlock support system 160 which only requires connection ofPV frames 212 to the three purlins 180 as shown. In other embodiments itis desired to minimize the size of frames 212, therefore additionalpurlins may be used, but still not as many prior art systems require. Inother embodiments brackets 132 are formed in different shapes tofacilitate connection to the shape of mounting surface 144. For example,some are shaped to compress a portion of an I-shaped beam whereas othersare adapted for connection to circular pipe. Still others are formed as“legs” to allow tilting up one side of an array 10. One skilled in theart will recognize that there are many different types of brackets whichmake up the entire scope of the inventive device. Thus, any bracketwhich has one portion shaped to optimize connection to a mountingsurface 144 and another portion which is shaped to optimize connectionto at least one PV frame 212, is a suitable bracket 132 for use with thepresent invention.

FIGS. 53-54 show an alternate embodiment of PV array 10 which furthercomprises a snap-in conduit box 195. FIG. 53 depicts a perspective viewof two interlocked PV modules 12A, 12B which are at the end of a row.FIG. 54 shows a perspective view of conduit box 195. Conduit box 195snaps into slots 26A, 26B via spring clips 197. Hole 196 in the rear ofconduit box 195 allows wiring from array 10 to pass into box 195, thenout through conduit 198 connected to box 195. An optional cover platefor conduit box 195, as are typical in the art, is not shown here. Useof conduit box 195 along with PV array 10 greatly simplifies wiringsince all wiring can be routed through gaps between PV modules 12, theninto conduit box 195 and out through conduit 198 to inverters or othersystem equipment. PV installers commonly fashion means for connectingjunction boxes to PV array support structures via strut and othermaterials. However, a ready-made box saves time in cutting strut andcustom rigging for each job. Conduit box 195 may also enhance theaesthetics of array 10 since it may be manufactured to match PV modulesframes. In other embodiments conduit box 195 is more firmly attached toframes 12A, 12B by connecting it via bolts or couplings 50 j instead ofspring clips 197, in a similar way to the connection of series couplingportions as shown in the second embodiment above. In still otherembodiments conduit box is replaced by a simple plate for receiving astrain relief or conduit coupling.

FIG. 55 depicts a perspective view of an alternate embodiment of PVmodule 11 as shown in FIG. 1. A PV module 411 with a PV laminate 420 anda frame 412 is shown. Frame 412 comprises two frame members 413 withslots 426 on opposite sides of a laminate back plane or base 409.Devices such as base 409, as are known in the art, may serve to insulatea roof or provide structural support to PV laminate 20 or both. Base409, however, is not rigid enough to fully support PV laminate 420, andthus frame members 413 are glued, fastened, or otherwise adhered to base409 or laminate 420 or both in order to provide structural support to PVmodule 411 and to provide a means for interlocking the sides of an arrayof PV modules 411 together. Base 409 may be adhered to the underside ofPV laminate 420. Since PV laminate 420 is supported by frame members 413and base 409, it may overhang frame members 413 as shown. In anotherembodiment frame members 413 enclose base 409.

Other embodiments add different features. For example, one embodimentadds a ball and detent to locking portion 104A, 104B to prevent lockingportion 104A, 104B from disengaging or working its way free and providea position location stop. Another provides a quick-release handleattached to rotating portion 100. The handle is tucked just lower thanlaminate 20 height when in locked mode and can be rapidly rotated by useof a finger-hold. Such a feature may be of use to firemen in anemergency. Another embodiment provides a locking portion which comprisesan expansion bolt. Other embodiments provide various devices which snapinto or connect to slot 26 such as: tool holders, tools, string lineholders, lights, fasteners, cosmetic flashings, architectural features,snow guards, debris screens, rodent screens, signs, cable clips, birddeterrents, and electrical connector housings.

While a number of exemplary aspects and embodiments have been discussedabove, those of skill in the art will recognize certain modifications,permutations, additions and sub-combinations thereof. It is thereforeintended that the following appended claims and claims hereafterintroduced be interpreted to include all such modifications,permutations, additions, and sub-combinations as are within their truespirit and scope.

1. A photovoltaic module comprising a first and a second frame memberconnected to form a corner, each frame member having a grooveessentially along its length, wherein: said grooves face outward,comprise an opening height, and are essentially contiguous at saidcorner, said opening height being essentially constant or increasing atsaid corner.
 2. A photovoltaic module according to claim 1, wherein saidgrooves are essentially continuous with each other at said corner.
 3. Aphotovoltaic module according to claim 1, wherein said grooves eachcomprise an end, and said ends are essentially open at said corner.
 4. Aphotovoltaic module according to claim 1, wherein said groove of saidfirst frame member is adapted to receive a coupling in a first directionproximate said corner and said groove of said second frame member isadapted to receive said coupling in a second direction proximate saidcorner, said first and second directions being substantially orthogonal.5. A photovoltaic module according to claim 1, wherein said groove facesoutward and said first and second frame members comprise an inwardfacing groove adapted to at least partially retain a portion of aphotovoltaic laminate.
 6. A photovoltaic module according to claim 1,wherein said first and second frame members are orthogonally connectedsubstantially at an end of each of said frames members.
 7. Aphotovoltaic module according to claim 1, wherein said photovoltaicmodule comprises a third and fourth frame member, each of said third andfourth frame members having a groove essentially along its length,first, second, third, and fourth frame members connected to form fourcorners.
 8. A photovoltaic module according to claim 1, wherein saidphotovoltaic module comprises a third and fourth frame member connectedat a second corner, each of said third and fourth frame members having agroove essentially along its length, wherein said grooves of said thirdand fourth frame members face outward, have essentially the same heightat said second corner, and are essentially contiguous at said secondcorner.
 9. A photovoltaic module according to claim 1, wherein anopening of said groove comprises a pair of facing flanges.
 10. Aphotovoltaic module comprising a first and a second frame member, eachframe member having an inward groove and an outward groove, wherein:said inward grooves are adapted to at least partially retain a portionof a photovoltaic laminate, said first frame member is orthogonallyconnected to said second frame member, and said outward grooves areessentially contiguous.
 11. A photovoltaic module according to claim 10,wherein said orthogonal connection is at an end of each of said framesmembers.
 12. A photovoltaic module according to claim 10, wherein saidoutward grooves are essentially continuous with each other through saidcorner.
 13. A photovoltaic module according to claim 10, wherein saidoutward groove of said first frame member is adapted to receive acoupling in a first direction proximate an end of said first framemember and said groove of said second frame member is adapted to receivesaid coupling in a second direction proximate an end of said secondframe member, said first and second directions being substantiallyorthogonal.
 14. A photovoltaic module according to claim 10, wherein anopening of said outward groove comprises a pair of facing flanges.
 15. Aphotovoltaic module comprising a first and a second frame member, eachframe member having an inward groove and an outward groove, wherein:said outward grooves meet at a corner and are adapted to receive acoupling proximate said corner.
 16. A photovoltaic module according toclaim 15, wherein said grooves are further adapted to receive saidcoupling essentially at said corner.
 17. A photovoltaic module accordingto claim 15, wherein an end of said outward groove of said first framemember is adapted to receive said coupling in a first direction and anend of said outward groove of said second frame member is adapted toreceive said coupling in a second direction, said first and seconddirections being substantially orthogonal.
 18. A photovoltaic moduleaccording to claim 15, wherein said outward groove of said first framemember is adapted to receive said coupling in a first directionproximate said corner and said outward groove of said second framemember is adapted to receive said coupling in a second directionproximate said corner, said first and second directions beingsubstantially orthogonal.
 19. A photovoltaic module according to claim15, wherein an opening of said outward groove comprises a pair of facingflanges.
 20. A photovoltaic module according to claim 19, wherein atleast a portion of an outside surface of one of said facing flangesturns partly inward at said opening.